Overview

D 2 www.namc.danfoss.com 1.800.432.6367MOTION CONTROLS

IND.MC.12.15.01 Revised September 1, 2005

Danfoss VLT® 5000 Overview

ContentsD 2 Overview and FeaturesD 14 Performance DataD 28 General Technical DataD 32 DimensionsD 44 OptionsD 68 Ordering InformationVLT 5000 APU ProgramD 69 OverviewD 70 NEMA 1/12 Bypass PackageD 73 NEMA 1 Integrated APUsD 75 Ordering Information

There's a Drive to Meet Your NeedsFor cost effectiveness and system optimization, VLT 5000drives are available in different hardware configurations:

ST: StandardSB: Standard with dynamic brakeEX: ExtendedEB: Extended with dynamic brakeNEW! Available on VLT 5122-5552; 380-500 VAC units andVLT 5042-5352; 525-690 VAC units:DE: Extended with brake and fuse/disconnectDX: Extended with fuse/disconnectPS: 24V input for logic supplyPF: 24V input for logic supply and mains fusesPD: 24V input for logic supply and mains fuses/disconnectPB: 24V input for logic supply and mains fuses/disconnect

and dynamic brakeUnits with dynamic brake require an external brakeresistor to complete the installation.

The extended configuration offers connection terminalsfor load sharing capabilities between VLT 5000 units, plusinput terminals for a remote 24 VDC supply to maintainthe control card and logic during removal of the AC inputpower.

RFI filters are standard on all 1-10 HP (460 VAC) and 1-5HP (230 VAC) configurations and are available as a built-inoption for higher HP models.

Optimized Bookstyle Enclosure• Protected chassis (IP 20) enclosure• Saves panel space• Side-by-side flush mounting requires less panel space• 1-10 HP

Factory Installed Options in Drive’s Enclosure• Load sharing• 24 VDC backup supply connections• Dynamic brake module• RFI filter to meet CE directives

Exclusive Patented VVCPLUS Performance• Sensorless vector control• Fast response – 3ms ±1ms• Speed or torque control• Full torque down to zero speed (open loop)• Full torque at zero speed (closed loop)• Smooth torque ripple• Wide speed range• Four quadrant operation

Extended AC Line Voltage• 200 to 240 VAC ±10%• 380 to 500 VAC ±10%• NEW! 525 to 690 VAC ±10% for

40 to 350 HP range

VLT 5000 Series drives are available in a variety of enclosure styles and protective ratings.

Drives Solutionswww.namc.danfoss.com 1.800.432.6367 D 3

VLT

® 5000

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Protection Features• Self-testing• Overvoltage• Overcurrent• Undervoltage• Overload• Overheating• External fault• Electronic thermal• Ground fault

Applications

Constant Torque

• Conveyors• Palletizers• Centrifuges• Sequencing• Positioning• Synchronizing• Pumps• Tooling Machines• Hoists• Grinders

Variable Torque

• Pumps• Fans

Options• Remote keypad kit• Din rail adaptor kit• Brake resistors• EMC filters• Floor mounting kits

(125-500 HP)

Compact Enclosures for all VLT 5000 Units• Chassis• NEMA 1 (IP 20)• NEMA 12 (IP 54)• Available for units 1-550 HP• Side-by-side flush mounting

Extended Horsepower Range• NEW! Up to 550 HP high overload/650 HP normal

overload• 1-600 HP normal overload• Constant Torque (CT) or Variable Torque (VT) operation• High torque overload mode:

160% torque overload Constant Torque (CT)• Normal torque overload mode:

110% overload (CT/VT) allows units to be used at onegreater horsepower level for 100% continuous outputwith 110% torque overload capability

New Display/Keypad• Removable Local Control Panel (LCP) allows

downloading of program from drive to drive• Displays multiple setup parameters• Quick menu setup for easy commissioning• Easy remote mounting of LCP

Enhanced Software• Automatic motor adaptation• Built-in PID control• Multiple data menu sets for quick system changeover• Open or closed loop motor thermal protection• Closed loop speed control available standard

International Approvals• UL• cUL• CE



Features – Keypad and Display FunctionsFast, Simple, Automatic Start-Up The VLT 5000 Series has a two-level, menu-promptedsoftware structure. The first level, referred to as the QuickSet-Up Menu (see facing page), contains the thirteenmost commonly used parameters; the second level offerscomprehensive programming capabilities.

If the drive and the motor are of the same rated size,programming is not normally necessary – simply connectthe AC line, the motor and the control wires, and start theVLT 5000 Series unit.

Versatile Data DisplayThe VLT 5000 Series drive’s four line, alphanumeric, backlitLCD display is easy to read from any angle. The display hasthree lines of 20 characters and one line of eight double-sized characters.

Up to four measurements can be shown continuouslyon the top two lines of the display. Choose from twenty-five different items to display, including input reference,motor current, hours run, output frequency, horsepower,kW or kWh, or select from custom units, such as GPM.

Local Control PanelAll VLT 5000 Series drives use the same control panel,menu-driven operating system and cabling connections.Once familiar with one drive, an operator can startup, program and operate any other VLT 5000 drivethroughout the HP range.

• Interchangeable keypad contains non-volatilememory for uploading/downloading parameters forsingle and multiple drive installations.

• LCPs may be removed for secure, tamper-proofoperation. (The drive’s status lights operateindependent of keypad). The operational status on thedrive include green "ON," yellow "WARNING," and red"ALARM" LEDs.

• The LCP on all units can be mounted up to 10 feet (3meters)from the drive using the optional NEMA 12mounting kit (ideal for machine panel mounting).


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IND.MC.12.15.01 Revised September 1, 2005V

LT® 5000

Features – Quick Set-up MenuQuick Start UpWith the direct-access Quick Menu, most installationsare commissioned by simply scrolling through the13 parameter settings to confirm that they matchyour requirements. Once checked, the values set areautomatically stored in non-volatile memory. That’s it!

After setting up one drive, the removable LCP can be usedto transfer the same settings to all other VLT 5000 Seriesdrives. Quick Set-up Menu items include:

• Language select

• Motor power

• Motor voltage

• Motor frequency

• Motor current

• Rated motor speed

• Automatic motor adaptation

• Minimum reference

• Maximum reference

• Ramp up time

• Ramp down time

• Local/remote control

• Local reference

The “+” and “-” keys are used to scroll and select thedata values. For example, in the Language set-up menu(above), the “+” and “-” keys scroll through the choices ofnine languages. Once the desired language is selected,pressing the Menu key stores the data value.

The optional LCP-2 Keypad/Display provides all thefeatures and performance benefits of the VLT 5000 SeriesLCP, and is also interchangeable with the VLT 2800 Seriesdrives.



The VLT 5000 with VVCPLUS

VLT 5000 Series features an inverter control system calledVVCPLUS, which is a further development of the VoltageVector Control (VVC) from the Danfoss VLT Series 3000.

VVCPLUS controls an induction motor by energizing it witha variable frequency and a voltage that matches it. If themotor load is changed, the magnetization of the motorchanges too, and so does its speed. Consequently, themotor current is measured continuously and the actualvoltage requirement and slip of the motor are calculatedfrom a motor model. Motor frequency and voltage areadjusted to insure that the motor operating point remainsoptimal under varying conditions.

The development of the VVCPLUS principle is the result ofa wish to maintain robust, sensorless regulation that istolerant to different motor characteristics without motorderating.

First and foremost, the current measurement and themotor model have been improved. The current is split intomagnetizing and torque-generating parts and providesfor more accurate and quicker estimation of the actualmotor loads. It is now possible to compensate for rapidload changes. Full torque as well as extremely accuratespeed control can now be attained at low speeds or evenat standstill.

In a “special motor mode,” permanent magnetsynchronous motors and/or parallel motors can be used.

Compared with a standard voltage/frequency control,VVCPLUS offers improved dynamics and stability, bothwhen the speed reference and the load torque arechanged. In addition, we have implemented a fullydigitalized protection concept, which insures reliableoperation even under the worst possible operatingconditions. Naturally, the VLT 5000 Series also offersfull protection against faulty coupling, short-circuiting,ground fault and overload.

Danfoss drives with the VVCPLUS control system tolerateshock loads throughout their speed range and reactswiftly to changes in reference.

Features – VVCPLUS: The Heart of VLT 5000 Technology

Oscilloscope trace of a motor phase current provided by a conventional pulse width modulation system with harmonic elimination (left); a Danfoss VVCPLUS system (right).

Advantages of VVCPLUS

• Up to 160% torque for up to 1 minute• Up to 180% starting breakaway torque (0.5 sec.)• Up to 100% acceleration torque of rated torque• Accurate slip compensation• Full torque (up to 100%) down to 0 rpm in open loop

control• Full holding torque (up to 100%) at 0 rpm in closed

loop control• Fast compensation for speed variations with load

changes• High speed stability• High resolution of output frequency• Fast system response of 3 ms (±1 ms)• No motor derating• Maximum stability during load changes

Quick, Complete Control In order to make programming simple and easy to grasp,we have included special features such as a Quick Menuand easy data transfer.

The Quick Menu guides users through the programmingof the few parameters that are typically needed to getstarted. For more complex operations, users can create,modify and store up to four different control programstailored to precise application requirements using theuser-defined setups in the Menu Mode.

The LCP (Local Control Panel) is detachable. It features afour-line alphanumeric display, enabling four measuringvalues to be displayed at the same time. Using thedetachable LCP, programmed settings can be copied fromone VLT 5000 Series unit to the next, eliminating timespent programming when changing drives or integratinga new drive into the installation.

The entire programming process is easier than everbefore. The VLT 5000 Series makes most adjustmentsautomatically.


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LT® 5000

Features – Installation and Start-up

123456789

10111213

LanguageMotor OutputMotor VoltageMotor FrequencyMotor CurrentRated Motor SpeedAutomatic Motor AdaptationMinimum FrequencyMaximum FrequencyRamp-Up Time 1Ramp-Down Time 1Local/Remote ControlLocal Reference

Display Mode

Setup 12

34

Group

0

1

2

3

4

5

6

Parameters

000-099

100-199

200-299

300-399

400-499

500-599

600-699

Description

Operation and Display

Load and Motor

References and Limits

Inputs and Outputs

Special Functions

Serial Communication

Technical Functions

Quick Menu Mode Menu Mode

Choice of Overload Torque Modes can Dramatically Reduce Drive CostThe VLT 5016 and above are software selectable toperform in two operating modes depending on therequirements of the application.

In High Overload torque mode, the VLT 5000 Seriesprovides up to 160% overload torque for 1 minute usingan appropriately sized motor. For many applications,however, this high overload torque is unnecessary.

With the VLT 5000 Series Normal Overload torque modefeature, the drive can now provide up to 110% for 1minute in constant torque at one HP size larger.

What’s the advantage? Used in conjunction with anoversized motor, a VLT 5000 Series drive operating inNormal Overload mode can provide a substantial increasein constant torque horsepower without derating.

Normal Overload mode gives the VLT 5000 Seriesdrive the ability to operate ”one power size higher.” Forexample, a drive rated for 15 HP constant torque (with a160% overload rating) can now provide 20 HP constanttorque (with a 110% overload rating). Obviously, ifthe application can allow the reduced overload rating,this VLT 5000 Series design feature can be a major costsavings when specifying a drive.

Excellent Torque ControlGood torque control properties, smooth transitions toand from current limit operation and robust pull-outtorque protection are insured.

After automatic motor adjustment, VVCPLUS will help toinsure extremely accurate motor control.

The VLT 5000 Series design accommodates a numberof integral components that would normally have tobe purchased and installed separately. These integralcomponents, such as DC coils and serial communicationport (standard), RFI filter and dynamic brake (optional),are space-savers that simplify installation, save cost andensure optimum performance.



Features – Built-in Protection

VLT 5000 Series has Built-in Protection to Maximize System Reliability Against:• System overloads• Motor failures• Heat• Voltage disturbances• Power surges• Loss of phase• Phase-to-phase and phase-to-ground short circuit• Ground fault• Switching on input/output• Electrical disturbances

Input Line Protection from Extreme Running Conditions

Line Disturbances and Transients

To protect itself from AC line voltage disturbances, thedrive monitors all three phases and interrupts driveoperation for phase loss or if there is phase imbalance.Transients on the AC line are suppressed by MOVs aswell as zener diodes for extreme transients. Danfossdrives meet VDE 0160 (European standard) for transientprotection.

Voltage Sags and Surges

The VLT 5000 Series is designed for a wide range ofoperating conditions. The 230 volt drives will operate on180–264 VAC. The 460 volt drive will operate from 342–550 VAC. The 575 volt drive will operate from 495–660VAC. The 690 volt drive will operate on 472-759 VAC . Fullrated motor voltage and torque can be delivered downto 10% under nominal AC line voltage. During an AC linedrop-out, the VLT 5000 continues until the intermediatecircuit voltage drops below the minimum stop level,which is typically 15% below the VLT 5000 Series lowestrated supply voltage.

Short Circuit

The VLT 5000 Series is protected against short circuitsby means of current measurement in each of the threemotor phases. A short circuit between two output phaseswill safely shut down the inverter when the short circuitcurrent exceeds the permitted value.

Ground Fault

The VLT 5000 Series provides complete protection frompotentially damaging ground fault conditions:

• On the supply side• On the motor side• In the control leads


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LT® 5000

Minimal Harmonic DistortionThe DC link inductor reduces the harmonic distortioncurrents that an adjustable frequency drive injects backinto the AC line. A properly sized inductor, such as that ina VLT 5000 Series, can reduce line harmonic currents to40% or less of the fundamental current. This eliminatesthe need and cost of additional AC line reactors and theirresultant line voltage reduction.

VVCPLUS Output Switching PatternUnique digital VVCPLUS voltage vector control provides:

• Nearly perfect output sine wave• Fully rated motor voltage at rated frequency• High efficiency for both drive and motor• Full motor performance without derating

Output ProtectionVLT 5000 Series drives incorporate both DC-link filters andmotor output protection as standard design features. Thisprovides short circuit protection and allows unlimitedswitching on the output without damage to the drive,eliminating the need for additional output reactors orswitch interlocks.

The DC-link filter improves overall efficiency by increasingthe power factor and lowering the ripple current in thebus voltage for an almost threefold increase in capacitorand drive life. As a result, motor operation is smooth andquiet and longer motor life can be expected.

Features – Built-in ProtectionExclusive “Soft Turn On” IGBT TechnologyWith the patented Danfoss “soft turn on,” the IGBTtransistors produce one of the lowest dV/dt in theindustry.

• Motor cable lengths up to 1,000 feet standard• Motor output reactors provided as standard on all

drives 125 HP and larger• Unlimited switching on the output

Thermal Protection for the Drive and MotorThe ETR (Electronic Thermal Relay) is an open loopmethod built into the VLT 5000 Series software to guardagainst motor overheating – requiring no additionalsensors or wiring. This function is UL recognized (Class 20)as an effective guard against motor thermal overload.

The VLT 5000 Series has drive thermal protection and alsoaccepts thermistor signal input from the motor to createclosed loop thermal protection for the entire system.



VLT 5000 Series Enclosures The VLT 5000 Series is available with Chassis (IP 20), NEMA1 or NEMA 12 enclosures.

Chassis Enclosures

Our Chassis enclosures allow easy mounting in panels,quick access to terminals and greater heat tolerance.

NEMA 1 Enclosures

All NEMA 1 drives are designed for minimal width,allowing drives to fit into crowded equipment rooms.Multiple drives can be mounted with no side clearance.Conduit entry is provided on the bottom of all drives.

NEMA 12 Enclosures

VLT 5000 Series units provide one of the most compactand cost effective NEMA 12 solutions on the market.Now the increased environmental protection offeredby a NEMA 12 enclosure can fit both the equipmentroom and the budget. High power VLT Series units (≥125HP) provide an optimum, dedicated NEMA 12 (IP 54)enclosure – the smallest package on the market.

MountingAll VLT 5000 drives provide for a vertical wall-mountingarrangement. Most VLT 5000 Series drives allow for side-by-side mounting with zero side clearances.

HumidityThe VLT 5000 Series has been designed to meet the IEC68-2-3 standard, EN 50178 pkt. 9.4.2.2/DIN 40040, class E,at 40°C. See Specifications section for further information.

The new high power VLT 5000 Series drives are available in Chassis, NEMA 1 and NEMA 12 enclosures.

Features – Enclosure ProtectionEnclosure Finishes

Enclosure VLT 5000 VACStyle Model Class MaterialChassis (IP00) 5032-5052 230 Steel 5122-5552 460 Steel 5042-5352 690 SteelProtected Chassis (IP20) 5001-5027 230 Aluminum 5001-5102 460 Aluminum 5001-5032 575 AluminumNEMA 1 (IP21) 5001-5027 230 Aluminum 5032-5102 230 Steel 5001-5552 460 Aluminum 5001-5032 575 Aluminum 5042-5352 690 AluminumNEMA 12 (IP54) 5001-5027 230 Aluminum 5032-5052 230 Steel 5001-5552 460 Aluminum 5042-5352 690 Aluminum

Vibration and ShockThe VLT 5000 Series is tested to the following standards:

• IEC 68-2-6; Vibration (sinusoidal)• IEC 68-2-34; Random vibration broad-band – general

requirements• IEC 68-2-35; Random vibration broad-band – high

reproducibility• IEC 68-2-36; Random vibration broad-band – medium

reproducibilityVLT 5000 Series drives comply with requirements thatcorrespond to conditions when the unit is mounted onthe walls and floors of production premises, as well as inpanels bolted to walls or floors.

Conformal CoatingSome applications require the drive to be operatedin environments with airborne contaminants, such aswastewater treatment plants and paper pulp plantswhere corrosive gasses are present. These corrosive gasesattack components in the drive; in particular, printedcircuit assemblies and their components. High humidityand high ambient temperatures exacerbate the situation.

Conformal coating is used to mitigate these corrosiveeffects. Danfoss has chosen a protective polyurethanecoating that has good resistance to chemicals andfungus and meets UL requirements for use in electroniccontrols. Performance of the coating has been verified byindependent laboratory testing of VLT 5000 Series using

NEW! 350 to 550 HP380-500 VAC

NEW!40 to 350 HP525-690 VAC


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1

2

3

4

5

Features – Speed Control

Speed Control of a Grinding MillA chemical processing plant has a unit that grinds solidmaterials into finer grain sizes. The grinding mill (2) runsat fixed speed.

Internal parts of the grinding mill are occasionallydamaged when they encounter pieces of hard materialsuch as stones or tramp metal. The tank (1) oftenbecomes overfilled, causing the grinding mill motor tooverload and trip. Frequent starting and stopping causeshigh maintenance costs of the mill and drive train.

When the silo (3) becomes too full, material drops ontothe conveyor (5) and spills over onto the floor due toexcessive pressure at the silo discharge.

Solution

The grinding mill (2) runs at variable speed and iscontrolled by a VLT Adjustable Frequency Drive. The max.torque is set to a value that causes the VLT to go intocurrent limit when the grinding mill is blocked. A stallmonitor automatically cuts off the line contactor if thegrinding mill slows down to an adjustable preset lowspeed limit and the grinding mill can be manually cleared.

If the grinding mill is partially blocked or overloaded bytoo much material in the tank (1), the VLT can remain incurrent limit and the grinding mill will continue to runat reduced speed. If the flow of material into the tank istemporarily stopped, the grinding mill can usually clearitself.

The speed of the grinding mill is dependent upon thelevel in the silo (3). The level controller (4) sends a signalto the VLT to regulate the level by controlling the speed ofthe grinding mill motor.

The setpoint of the level controller keeps the level in thesilo constant, therefore the pressure at the silo dischargeis kept constant, thus controlling the amount of materialdischarged onto the conveyor.

Advantages

• The adjustable current limit and the built-in tripfunction prevent mechanical overload.

• A starting torque up to 160% of nominal motor torqueenables restart of the grinding mill.

• The electronic reversing feature incorporated in theVLT helps to eliminate blocking and jamming.

• Less material spills over the conveyor onto the floor.• Greater control reduces maintenance costs and

downtime.• The unit can be rapidly reset for different types of

materials.• The slip compensation feature in the VLT gives near

constant speed that varies less than 1% with changingload.

both coated and uncoated printed circuit assemblies inIP 20 and IP 54 versions.

Note: VLT 5352-5552; 460 V and VLT 5042-5352; 690 Vunits supplied with conformal coating standard.

CoolingDanfoss VLT Series units are all designed for optimumthermal efficiency. On the high power units (>125 HP/460VAC), the power component cooling air and internalelectronics air are isolated, preventing the potentialintroduction of contaminants.



Shown below is how a VLT 5000 Series typically interfaceswith other components in a system. The terminalnumbers and functions are identical on all VLT 5000 Seriesdrives.

The analog, digital and relay terminals are allprogrammable. The functions shown here are typical, butshow only a small portion of the total capability.

Optional relay output cards provide up to four additionalrelay outputs.

Control Card BenefitsThe standard I/O supplied on the VLT 5000 drive is equalto or greater than that supplied by most competitordrives featuring extended I/O options.

Standard I/O Includes:• 8 digital inputs• 2 pulse/encoder inputs• 3 analog inputs• 2 digital/pulse and analog outputs• 2 relay outputs

+10 V DC

91 (L1)

92 (L2)

93 (L3)

99 (PE)

88 (-)

89 (+)

50 (+10 V OUT)

53 (A IN)

54 (A IN)

55 (COM A IN)

60 (A IN)

12 (+24 V OUT)

13 (+24 V OUT)

16 (D IN)

17 (D IN)

18 (D IN)

19 (D IN)

20 (COM D IN)

27 (D IN)

29 (D IN)

32 (D IN)

33 (D IN)

Motor

(U) 96

(V) 97

(W) 98

(PE) 95

(AUX RELAY) 01

(AUX RELAY) 02

(AUX RELAY) 03

(RELAY) 04

(RELAY) 05

(COM A OUT) 39

(A OUT) 42

(A OUT) 45

(P RS-485) 68

(N RS-485) 69

(COM RS-485) 61

Output Speed Indication*0/4 - 20 mA

Output Current Indication*0/4 - 20 mA

Run Indication*50 VAC, 1 A Max

Fault Indication*240 VAC, 2 A Max

• These terminals can be programmed for other functions

RS-485

+

-

Reset*

Preset Speed

Run/Stop*

Reverse*

Q Stop

Jog

Setup Select*

Setup Select*

0/4 - 20 mARef. Input*

0 - 10 V DCRef. Input*

0 - 10 V DCRef. Input*

ExternalDC Bus

Connection

3-PhasePower

Input

Brake Resistor

(R-) 81

(R+) 82

35 (-)

36 (+)

External24 V DC

Supply

Features – Inputs and Outputs


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LT® 5000

IsolationAll analog and digital inputs and outputs and the RS485serial communication port are galvanically isolated.Because these points do not share a common, the drivewill not induce ground loop problems.

In the VLT 5000 Series, all control terminals as well asterminals 1-5 (AUX relays) are supplied by or connectedto circuits that comply with PELV (high impedance)requirements in relation to the AC line potential.

Analog InputsTwo analog inputs for voltage signals and one input forcurrent signals are provided for reference and feedbacksignals. A thermistor can also be connected to eithervoltage input. The two analog voltage inputs can bescaled in the range of 0-10 VDC; the current input in therange of 0-20 mA.

Digital InputsThe VLT 5000 System offers eight fully programmabledigital inputs for over thirty functions.

Pulse/Encoder InputsTwo inputs are available for pulse scaling or for feedbackfrom up to two encoders.

Relay OutputsRelay outputs may be selected to indicate thirty differentfunctions such as ready, run, trip, current above acustomer preset value, current above current limit,frequency within customer preset limits, frequencyabove a customer preset value, electronic motorovertemperature protection warning, or that remoteoperation mode has been selected.

Digital/Pulse and Analog OutputsThe two digital/pulse and analog outputs can beprogrammed for digital, pulse scaling or analogfunctions. When used as a digital output, the VLT 5000presents status with a 0 or 24 VDC signal. Pulse scaling isalso available for following power, torque, frequency orcurrent. The drive supports two types of analog signals: 0-20 mA and 4-20 mA. The terminals can also be configuredfor voltage output (0-10 V) with the addition of a pull-down resistor.

Features – Inputs and Outputs

Overview

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